Recovery of sulfur dioxide from waste gas

ABSTRACT

SULFUR DIOXIDE IS RECOVERED FROM GASES CONTAINING IT BY CONTACTING THE GAS WITH AQUEOUS CESIUM OR RUBIDIUM SULFITES TO PRODUCE THE CORRESPONDING BISULFITE AND SUBSEQUENTLY SEPARATING THE BISULFITE AND SO2-PARTIAL PRESSURE LOWERING MATERIALS TO OBTAIN PURER BISULFITE OR PYROSULFITE WHICH CAN BE DECOMPOSED TO RELEASE SULFUR DIOXIDE.   D R A W I N G

Aug 29, 1972 J. D. TERRANA ETAL 3,687,625

i RECOVERY oF SULFUR DIoxIDE FROM WASTE GAS 'I Aug. 29, 1972 J, Q TERRANA ETAL 3,687,625

RECOVERY OF SULFUR DIOXIDE FROM WASTE GAS l Original Filed Nov. 9. 1967 2 SheetsgShQQtj 2 N lll ACTI/A70@ INVENTORS 117 mwwm ATTORNEYS United States Patent O1 hee 3,687,625 RECOVERY OF SULFUR DIOXIDE FROM WASTE GAS Jack D. Terrana, Tampa, and Leo A. Miller, Lakeland,

Fla., assignors to Wellman-Lord, Inc., Lakeland, Fla. Continuation of application Ser. No. 681,775, Nov. 9,

1967. This application Sept. 14, 1970, Ser. No. 72,175

Int. Cl. C01b 17/56 U.S. Cl. 423-242 45 Claims ABSTRACT OF THE DISCLOSURE Sulfur dioxide is recovered from gases containing it by contacting the gas with aqueous cesium or rubidium sultes to produce the corresponding bisuliite and subsequently separating the bisulte and SO2-partial pressure lowering materials to obtain purer bisulte or pyrosulte -which can be decomposed to release sulfur dioxide.

This application is a continuation of yapplication Ser. No. 681,775, led Nov. 9, 1967.

This invention relates to the recovery of sulfur dioxide from sulfur dioxide containing gases.

According to one existing practice, sulfur dioxide can be recovered from gases containing large concentrations thereof, e.g. 5 to 20 weight percent sulfur dioxide, by cooling and scrubbing the gas with water which dissolves the sulfur dioxide and then heating the resulting solution to drive off the sulfur dioxide. This process, however, requires -large quantities of water and fuel and is correspondingly expensive since the solubility of sulfur dioxide in -water is not very high and depends upon the percentage of sulfur dioxide in the gases and the temperature of the water used for absorption. Accordingly, this process iS generally unsuitable for use with gases containing small concentrations of sulfur dioxide.

Sulfur dioxide, is, however, found in significant amounts as a constituent of many waste gases such as smelter gases, oifgases from many chemical plants, and stack or furnace gases from coal-burning furnaces such as used in electric power plants, although its concentration in such gases is from about 0.001 to less than about 5 mole percent and frequently is less than about 0.5 mole percent (about l percent by weight). For example, a modern electric power plant of 1,350,000 kw. capacity will burn about 15,000 tons of coal per day. Much coal contains about 3.5 weight percent sulfur, or even more. The emission of sulfur dioxide from a plant of this size -using such coal would then amount to about 1,000 tons per day, although the concentration of sulfur dioxide in the stack gases can be very low, for instance on the order of 0.2 to 0.3 mole percent, depending upon the sulfur content of the coal.

This invention provides for the recovery of sulfur dioxide present in such small concentrations as well as in large concentrations in gases and thus provides for significant abatement of sulfur dioxide-air pollution although it is not limited thereo. Significant amounts, for instance greater than about 75 weight percent, of sulfur dioxide can be removed from such gases.

In accordance with this invention, sulfur dioxide in the waste gas is reacted with a sulte of cesium or rubidium in aqueous solution to form an aqueous solution of the corresponding bisulte and substantially reduce the sulfur dioxide content of the gas, for instance to less than about 0.02 mole percent in a stack gas containing more than about 0.2 mole percent. The bisulte is separated, e.g. crystallized, and can be recovered in crystalline form as pyrosulfite which is subsequently decomposed to 3,687,625 Patented Aug. 29, 1972 produce the corresponding sulfte and sulfur dioxide. The bisulte is transformed to pyrosulte during crystallization. The sulfur dioxide is drawn off and can be either cooled and compressed to provide a liquid product or sent as a gas to a sulfuric acid plant. The sulte can be recycled to the reaction zone wherein additional sulfur dioxide is absorbed. The reactions utilized in this invention include:

Il. cool Bisulfite Pyrosulfitc (c) -l- H2O III. heat Pyrosulfite Sulflte -l- S02 (g) For Reaction I to proceed, the temperature should be maintained above the temperature at which sulfur dioxide is absorbed by reaction with the aqueous solution of sulte, and below the temperature at which bisulte decomposes or Reaction III proceeds, e.g. below about 230 F. In general, the cooler the solution of sullite, the more readily sulfur dioxide will be absorbed by the solution and react with the sulfite. With stack or furnace gases, however, the temperature of the solution will generally be above about F. or 100 F. to avoid the need for refrigeration, although ambient temperatures are suitable. Preferably, the temperature is maintained below about F., eg. at about 120 to 180 or 185 F., since above these temperature ranges Reaction I begins to slow to a point where sulfur dioxide will not be readily absorbed into solution because the partial pressure of the sulfur dioxide becomes too high.

The solution resulting from a reaction of an aqueous solution of the sulite and a stack gas inherently contains many ingredients, for instance the following is an example:

Weight percent range The sulfur dioxide is present in chemically combined form, for instance as the bisulite, which can be considered a sulfur dioxide precursor in the solution and is present or in contact with SO2-partial pressure lowering materials for instance, metal salts, e.g. alkali metal salts, generally the respective cesium or rubidium salts such as the unreacted corresponding sulte and corresponding sulfate, produced by reaction between sulphur trioxide and the sulte. The purity of the bisulite in contact with the SO2- partial pressure lowering materials is generally less than about 60 wt. percent on a dry basis.

In accordance with an advantageous feature of the present invention suicient amounts of the SO2-partial pressure lowering materials are separated from the bisuliite to increase the partial pressure of the sulfur dioxide in the bisulfte. The separation of the SO2-partial pressure lowering materials can be effected by any suitable procedure, by for instance by selectively extracting the bisulte from the solution or by extracting any one of the SO2-partial pressure lowering materials from the solution. The separation is preferably conducted by crystallizng the bisullite (which transforms to the pyrosulte during crystallization) out of the solution for further treatment in accordance with the invention as set forth below.

The release of sulfur dioxide from a precursor such as the pyrosulte depends upon its partial pressure under given conditions, e.g. when in association with or without other materials including salts such as the corresponding sulfate and suliite which are generally present in the resulting solution produced by reaction of the suifur dioxide containing stack -gas with the aqueous solution of sulte. The partial pressure of sulfur dioxide in its precursor in the presence of other materials, e.g. the respective cesium or rubidium salts, in the reaction product solution at its boiling point at standard pressure conditions is so low that it can not be released in a feasible manner. In sharp contrast to this, its partial pressure when the pyrosullite is in relatively pure form is relatively high. The purity of the pyrosulte is increased in accordance with the present invention to generally greater than about 65 Wt. percent, preferably greater than about 90 or 95 wt. percent.

The cesium or rubidium bisulte can be advantageously separated or recovered advantageously in the form of the corresponding pyrosl-fite by crystallization from the SO2- partial pressure lowering materials in the solution. Crystallization of the pyrosullite can be accomplished using suitable crystallization procedures, for instance by supersaturating the solution by heating it in a vacuum or advantageously by cooling the aqueous bisulite solution to a temperature at which a substantial portion of the pyrosulite crystallizers, e.g. below about 100 F. or 110 F., with the lower limit being dictated by economics. Since the sulte is more soluble than the bisulite, substantially pure, e.g. greater than about 95 wt. percent, pyrosulfite crystals can be obtained.

The pyrosulte crystals can be separated, e.g. by separation techniques such as centrifugation or ltration and heated to the decomposition temperature therefor and under ambient pressure conditions, these temperatures are generally greater than about 100 F. and sufficient to decompose the pyrosulte, for instance above about 230 F. and up to about 600 F. but preferably below temperatures at which substantial amounts of the sulfate form, e.g. 400 F., and preferably above about 300 F. under essentially anhydrous condition, to release sulfur dioxide and convert the pyrosulfite to the corresponding sulfite which is suitable for reuse. This decomposition method eliminates the need to vaporize large amounts of water to remove sulfur dioxide when anhydrous conditions are desired. The hot sul-tite produced upon decomposition of the crystals can be combined with the filtrate resulting from the separation of the pyrosulite and recycled to the reaction zone.

The pyrosulte crystals are advantageously separated from an aqueous solution and the crystals wet with water can be heated to decompose them to produce sulfur dioxide. The pyrosulite crystals can be advantageously heated in the presence of water to enhance their decomposition to produce sulfur dioxide at relatively low temperatures. The water employed can be residual Water of the mother liquor contained by the crystals or it can be added water; it can be in any suitable form, e.g. liquid or vapor form; and it is used in amounts sufficient to enhance the decomposition of the pyrosulte to produce sulfur dioxide. These amounts are at least about 0.01 percent by weight, generally from about l to 99 weight percent and advantageously from about 20 to 75 weight percent based on the pyrosulte and water. In amounts up to about 20 weight percent water, damp crystals are provided and in amounts of about 40 weight percent, for instance, a solution can be provided. When in solution, however, the pyrosulfite is in the bisulte form.

The pyrosulite in the presence of, or in Contact with, water is heated to temperatures suficient to produce sulfur dioxide and temperatures generally from about 100 to 4 225 F., preferably from about 150 to 225 F. can be used under ambient pressure conditions.

The decomposition of the pyrosulte in contact with water can be conducted under ambient pressures or superatmospheric pressures, for instance from about 0 to 300 p.s.i.a., -generally from about 15 to 150 p.s.i.a. although ambient pressures can be advantageously employed. In a modification of this aspect of the present invention, superatmospheric pressures can be employed when the pyrosull-ite is in aqueous solution to increase the concentration of the solution at higher temperatures, e.g. above about 230 F. and up to about 375 F., with a consequent increase inthe partial pressure of sulfur dioxide in the pyrosulfte and an enhancement of the production of sulfur` dioxide. Generally the water employed in this aspect is from about 5 to 50 weight percent. For instance, if bisulte solutions are heated under a pressure of about p.s.i.a. with a temperature of about 350 F., the solubility of the pyrosulite crystal is much greater, e.g. about 75 weight percent based on the crystals and water. This higher concentration provides a much higher partial pressure of sulfur dioxide than at lower concentrations and the percent conversion of pyrosulte to sullite is greater.

Another advantageous feature of using water to enhance the decomposition of the pyrosulte at a lower ternperature is the obviation of use of an inert heating material which is desirable when heating pyrosulte in an essentially dry state to decompose it to produce sulfur dioxide gas. Relatively high temperatures, e.g. up to 400 F., are generally used under these dry-state conditions and the use of an inert heating material is generally desirable to maintain the suliite (which is also produced along with sulfur dioxide during decomposition of the pyrosulfte) in a liquid medium which occludes the sulte crystals and prevents contact with the sulfur dioxide. The partial pressure of the sulfite, like that of the sulfur dioxide, is also high enough to vaporize it and contaminate the sulfur dioxide product at these high temperatures and they may react to produce undesirable thiosuliite and sulfate. When used, the chemically inert heating material is one that is normally liquid under the temperature conditions employed and among those suitable are organic materials such as Dowtherm (a mixture of diphenyl and diphenyl oxide having a boiling point of about 525 F.) and mineral oil. The inert material is used in amounts suicient to form a slurry with the pyrosuliite crystals and these amounts generally range from about l0 to 90 wt. percent of inert material based on the inert material and the pyrosuliite.

The utilization of water to enhance decomposition of the pyrosulte is preferable to the anhydrous procedure since it obviates the desirability of using such inert materials and the expense of handling such materials and it provides for the production of sulfur dioxide at signicantly lower temperatures and a higher conversion of pyrosuliite (bisullite) to sulfur dioxide.

Since there is generally a small amount of sulfur trioxide present in waste gases containing sulfur dioxide, a small amount of sulfate is formed which is periodically removed. Additionally, oxygen present in the waste gases can react with the sullite to produce additional sulfate so that it may be desirable to add an oxidation inhibitor, e.g. organics such as hydroquinone, etc., to the sulte solution. The sulfate generally crystallizes with the pyrosulite and can be separated by periodically redissolving the pyrosulfite crystals, which are more soluble in water than the corresponding sulfate. The redissolvcd pyrosulte crystals can be recycled to the reaction zone after the solid sulfate is removed.

The present invention may be better illustrated by reference to the attached drawings and the following example, which are not to be considered as limiting the invention.

FIG. 1 is a liow sheet of a system for the recovery of S02 which system incorporates the present invention in an advantageous manner; and

FIG. 2 is an enlarged schematic view of the absorption column 10 in the system depicted in FIG. 1.

Referring now to FIGS. l and 2, a gas st-ream containing sulfur dioxide, e.g., ue gases from a power plant or waste gas from an industrial plant, e.g., a sulfuric acid plant or gas containing solid particulates from an aluminum plant, is introduced into reactor 10, having an inside diameter of 30 inches, constructed of 304 type stainless steel and having any suitable corrosion resistant matcrial liner 9 which is resistant against weak sulfuric acid, e.g. lead or suitable synthetic resin liners. The gas passes through line 12, having an internal diameter of twelve inches. The reactor is of a length of 2l feet from line B-B. The amounts and rates given throughout this speciiication for gas and liquid specifications are based upon a reactor having these dimensions for internal diameter, i.e. 30 inches or a cross-sectional area of about 4.9 square feet, and distances between components positioned in the reactor.

It willbe obvious to those skilled in the art that the amounts and rates of gases and liquids used will vary depending upon the size of reactor usedand the distances between components employed in the reactor, however, these can be referred to as equivalents within the scope of the invention.

The concentration of sulfur dioxide in such gases is generally from about 0.001 to less than about mole percent and frequently is less than about 0.5 mole percent (about l percent by weight). For example, a modern electric power plant of 1,350,000 kw. capacity will burn about 15,000 tons of coal per day. Much coal contains about 3.5 weight percent sulfur, or even more. The emission of sulfur dioxide from a plant of this size using such coal would then amount to about 1,000 tons per day, although the concentration of sulfur dioxide in the stack gases can be very low, for instance on the order of 0.2 to 0.3 mole percent, depending upon the sulfur content of the coal. Significant amounts, for instance greater than about 75 weight percent, of sulfur dioxide can be removed from such gases.

The Waste gases may also include S03, however the concentration of S03 will vary according to the source of the gases and even llame temperatures used in processing, among other factors. It will usually not be higher than about 0.01 mol percent of the gas, normally being within the range of about 0.0001 to 0.01 mol percent, usually the majority, e.g. more than about 70 percent, of the S03 in the gas is present as S03 adsorbed on the surface of particulate solids. A particular advantageous feature provided by a prescrubber, described below, resides in its capacity to remove minimal amounts, e.g. from about 0.00001 to less than about 0.005 mol percent, of liquid soluble components in the gas stream; this being particularly useful when the gas is treated preliminarily e by prescalping as described below and the residual amounts of S03 in the gas to be treated in the prescrubber are minimal.

The gas stream in line 12 is generally at a temperature of up to about 800 F., often about 150 to `600" F. For example, suitable gas streams for use in this process include flue gases from power plants burning coal or oil which typically have a temperature in the range of 250 or 300 to 360 or 400 F., off gases from sulfuric acid plants which typically have a temperature in the range of 150 to 200 F. and off gases from smelters which can have a temperature of up to about 800 F. However, at temperatures above about 400 F. it may be desirable to cool the gas to a temperature from about 225 F. to 300 F., e.g. by quenching with ambient air, to avoid deleteriously affecting the reactor, reactor lining or prescrubber operation. If the gases are below about 150 F., it may be desirable to heat the gas in line 12 to assist in removal of water from the solution in reactor 10. The flue gases will generally have a relative humidity up to about 10 percent, usually from about l to 7 percent.

Fan 28 in FIG. 1, which draws stripped gas from the reactor, can, if desired, be arranged to blow gas through the reactor. The stripped gases removed from reactor 10 via stack 14 and the incoming gases in line 12 can be passed in a countercurrent heat relationship through a heat exchanger (not shown), if desired.

Sulfur dioxide is absorbed from the gas stream in zone 30 of reactor 10 by absorption through reaction with an aqueous solution of cesium sullite to produce an aqueous solution of cesium bisultite, and the stripped gases are emitted through stack 14. Although this illustration will use cesium suliite, the corresponding sultite of rubidium can also be used.

The gases, e.g., iiue gases in this illustration, introduced through line 12 pass under bonnet 13 which is arranged over the inlet opening of line 12 into reactor 10 and which extends into the reactor 10 a suiiicient distance to prevent water or solution from passing in front of the inlet opening of line 12. It advantageously prevents plugging of inlet line 12 by components, e.g. fly ash, recovered from the gas in zone 20. Bonnet '13 extends upwardly at a slight angle to cause liquid to run back to the wall of reactor 10 and around the inlet opening of line 12 which is iiush with the wall of reactor 10. The angle of bonnet 13 is generally from about 5 to 60 degrees, preferably about l0 to 45 degrees, e.g. 30 degrees, and bonnet 16 has a diameter at least equal to the diameter of the inlet opening of line 12, e.g. a 12 inch internal diameter. The most upwardly projecting portion of the bonnet in zone 20 is located at a distance sutiiciently away from nozzle 25 to avoid destroying the spray pattern but close enough to avoid excessive vaporization of the mist from the spray and droplets falling off of the target and this distance is generally from about 5 to 70 inches, advantageously from about 10 to 30 inches, e.g. 15 inches, in the arrangements described herein. Any liquid running down the wall of reactor 10 or striking the upward surface of bonnet 113 thereby is directed away from the inlet opening and to the wall of reactor 10 without passing directly in front of the inlet opening.

Reactor 10, although advantageously shown as a single vessel, includes three zones which may, if desired, be separate units. These zones are a prescrubber zone 20, an absorption or reaction zone 30, and a moisture entrainment or demister zone 40.

The waste gases entering reactor 10 first pass through prescrubber zone 20 where particulate solid components, e.g. iiy ash, and water-soluble components, e.g. S03, hydrocarbons including methane, ethane, propane, etc., in the gas are selectively removed from the S02 containing gas, the S02 in the gas in turn being selectively removed from the gas in zone 30. Since a majority of the S03 in the gas is usually adsorbed on the surface of the solids in the gas, it is generally removed upon removal of the solid particles. The solids, e.g. dust, in the gases are generally unreacted materials, e.g. fly ash produced by the chemical plant, or non-combustible components of the fuel.

The chemical make-up of ily ash varies, of course, with the particular fuel being burned, but usually it is composed to a large extent of silica, alumina and iron, with other metal oxides such as oxides of manganese and vanadium frequently being present in minor amounts. Other suspended particulate solids which may be present in the waste gases include, for instance, particulate hollow carbon spheres which are particularly found in oil-burner off-gases, and which, like fly ash, contain significant quantities of adsorbed S03. The particle size of the suspended solids found in waste gases can be within about 0.5 to 50 microns, but may be much larger, however the predominant number of the particles range up to about l0 microns.

For instance, the fly ash in a ue gas produced from a coal plant using a Turbo feed coal grinding method had the following size distribution in the flue gas:

Weight percent Size in microns l of total ily ash -10 86 and from a coal plant using a cyclone feed coal grinding method had the following size distribution inv the flue gas:

Weight percent Size in microns of total ily ash The solids loading in gases can range from about 0.001 to 60 grains per cubic foot of gas, for instance, and for -iiue gases will generally range from about 1 to 10 grains per cubic foot. If the solids loading of the gas is very high, e.g. generally containing more than about l, e.g. from about l to 10 grains of solid per cubic foot of power plant iiue gas, which usually have about 1.2 to 4 grains of solid per cubic foot, and particularly if it contains large particles, e.g. having its longest dimension greater than about 1/16 inch, it may be desirable to prescalp the gas, for instance in an electrical precipitator or Cyclone separator, not shown, before introducing the gas in line 12. Generally from about 80 to 90 percent of the particulate solids can be removed by prescalping with a Cyclone separator and a greater amount with an electrical precipitator, which however, is more expensive than the separator.

While the interposition of devices such as electric precipitators and centrifuges, c g., dry cyclones, between the source of the waste gases and the chemical absorption zone will readily serve to preliminarily remove the bulk of the larger of such solid contaminants, in order to provide essentially complete removal of these solids prior to contacting the gases with the absorbing solution it has heretofore been necessary to employ a great number of such devices in series or parallel relationship. This results in high cost of operation or capital investment.l A particular advantageous feature provided by the prescrubber resides in its capacity to substantially remove even minimal amounts, e.g. from 0.001 up to about l grain per cubic foot of gas, of particulate solids which are not removed by the use of a separator or electrical precipitator and unless removed, would deleteriously affect the system; moreover, the solids are removed efficiently and with minimum capital cost.

Scrubbing water is introduced via line 24 to the lower section of reactor 10 and is upwardly discharged in the form of a tine spray through spray nozzle having an orifice generally suicient to provide 0.1 gallon per minute (g.p.m.) per 2000 cubic feet per minute (cfm.) of gas and producing spray in an arc generally from about 10 to 125, e.g. 75, having spray droplets ranging in size generally from about 200 to 800 microns, advantageously for removing particulates of a size up to about 60 microns. The temperature of the scrubbing liquid, e.g. water, is generally from about 50 to 120 F., preferably from about 70 to 90 F. A plurality of nozzles can also be employed as shown in FlG. 2. Positioned generally from about 4 to 18 inches, e.g` about 9 inches, above the nozzle 25 is a substantially horizontally disposed, lluid, e.g. gas or liquid, permeable i-mpingement target .assembly lhaving ylittle continuous extensive surface. It advantageously consists of columns or tubular members forming a lattice-like tray support 15, preferably formed from an expanded metal, e.g. stainless steel. Held by the support 15 is packing material 22 composed of about three layers of randomly arranged, nonporous, packing components, e.g. Raschig rings, Interlox or Berl saddles, preferably of ceramic composition, the individual components having a longest dimension generally from about 0.25 to 3.5 inches, e.g. 11/2 inches, and forming a packing column generally from about 1.5 to 5.5 inches in height and advantageously from about 3 to 4 inches in height, weighing generally from about 30 to 70 pounds per cubic foot and having generally from about 50 to 90 percent free space.

As indicated in the drawing, the spray nozzle 25 is positioned near enough to the support 15 to provide a continuous spray of water at a supercial velocity sufficient to overcome gravity, contact and wet the target surface, generally from about 2 to 20 fps., e.g. about 5 f.p.s. The water reaches, contacts and Wets the column support and the layer of packing material retained thereon, and falls downwardly as large droplets to carry away particulate solid and S03 components which are removed from the gas stream. The spray of water entraps the larger solid particles causing them to fall out of the gas stream while partially dissolving water-soluble S03 in the gas stream and, as the waste gas passes through the impingement material, substantially all, e.g. at least about percent, of the remaining smaller solids and S03 in the gas strike and stick to the wetted areas of the impingement material, forming droplets which enlarge to a point to overcome the force of gravity and adhesion to the surface of the material and fall or are washed oif of the impingement material by the spray of water. Generally, in excess of Weight percent, for instance in excess of 99 percent, of the particulate solids may be removed from the gas. The removal of S03 is particularly desirable since in this system it produces cesium sulfate which deleteriously affects the recovery of SO2 by, for instance by consuming cesium sulfte which would otherwise be consumed by SO2.

Waste gases entering the column via line 12 proceed upwardly through the support 15 and packing 22. The gas is advntageously contacted with the liquid by conducting the gas and liquid concurrently to a iluid, e.g. gas or liquid, -permeable impingement target; the gas being conducted to the target at a supercial velocity suicient at thetime of contact with the target to permeate and `pass through the target in the presence of a liquid being conducted to the target at a supercial velocity sufficient at the time of contact with the target to wet the target and insufficient to permeate the target in substanial amounts. Generally, the velocity of the gas to the target is suicient to have a predominant amount, for instance at least 60 volume percent and preferably from about 90 to 100 volume percent, permeate and pass through the target. Generally, the superficial velocity of the gas at the time of contact with the target will range from about 2 to 15 ips. and preferably from about 7 to l2 f.p.s., e.g. l0

The superficial velocity of the liquid at the time of contact with target is generally from about 2 to 15 f.p.s. and preferably from about 5 to 10 fps., e.g. 8 f.p.s. The amount of liquid employed is sulcient to effect transfer of particulate solid or liquid-soluble components in the gas to the liquid on Contact with the target and this will depend upon the amount of particulate solid or liquidsoluble components in the gas, generally the amount of liquid will range from about 0.01 to l gpm. per 2000 c.f.m. of gas containing from about 0.5 to 30 grains per cubic foot of particulate solid components and sucient to dissolve the liquid-soluble components in the gas. The pressure drop of the gas through packing 22 will generally range from about 0.25 to 0.5, e.g. 0.4, inches of water at 2000 c.f.m. of gas. Moreover, substantial interstitial holdups of liquid in the packing is avoided.

The liquid employed in the present invention can be any suitable liquid which is chemically inert to the impingement target and which does not deleteriously aiect the mass transfer, particularly when the mass transfer of non-solid components is involved, the liquid is advantageously one that will also selectively dissolve and remove the non-solid components. For instance, water can be employed to selectively and simultaneously remove particulate solids and S03 from a gas stream. Suspended solids present in the gases impinge upon and are restrained by the wet surface presented by both the support and the layer of packing material 22. These solids are washed olf the packing and support by the downwardly falling, spent scrubbing water which has been checked and driven back by the target assembly. The spent scrubbing water, containing removed solids and absorbed sulfur trioxide, flows by force of gravity down the funnel shaped sides of collection bottom 17 of column 10 and out the spent scrubbing water discharge line 26. An important feature is the positioning of a surface such as collection bottom 17 in a droplet receiving relationship with the impingement target to receive droplets falling off of the target and remove them from zone before substantial evaporation of the droplets can occur and thus substantially preclude the return of particulate solid, e.g. fly ash, or liquid-soluble, e.g. S03, components to the target by the incoming gases. Referring to FIG. 2, the distance between points a-a in this illustration is 6 feet and surface 17 projects downwardly at a 60 angle to outlet 26. Suspended solids and sulfur trioxide are thus removed from the waste gases before the latter come in contact with the chemical absorbing solution. If desired, the spent scrubbing Water, which may often have a pH of about 2 to 4, depending on the amount of sulfur trioxide in the waste gases, may be treated for separation and recovery of the solids, e.g., y ash, and the sulfuric acid. One highly advantageous feature of this prescrubbing arrangement is that low volurnes of water can be used to wet the impingement target, a particularly attractive feature since the amount of water within the present system can affect the overall efliciency of the process. Accordingly, it is desirable to only use an amount of water suflicient to contact, wet, and fall from the impingement target surface and collect the particulate solid materials and S03. Generally, less than about 0.1 g.p.m. of water, preferably from about 0.01 to 0.07 g.p.m., e.g. 0.05 g.p.m., per 2,000 c.f.m. of gases, are used The advantage of using less than about 0.1 g.p.m. is illustrated in Table I below By using this prescrubber arrangement, it is possible to control any increase in humidity of the gases passed through prescrubber 20 generally to not over about 8 to 10%, preferably 2%, and the temperature drop across the prescrubber is generally less than about 60 F., preferably less than about 50 F.

Use of the scrubbing apparatus described here and in the drawings, particularly in FIG. 2, has been found to provide, in addition to an extremely low temperature drop and minimal increase in the relative humidity of the gas across the scrubbing zone, particularly when processing gases at temperatures up to 500 F., also provides an assembly which is surprisingly free of plugging diiculties in contrast to a prescrubbing assembly employing continuous overhead water spray delivery which resulted in a significant temperature drop, e.g. about 100 F., and a significant increase in relative humidity, e.g. about 10 percent, and also became clogged within a short time, e.g. 2 hours, with solids removed from the gas stream. The positioning of the spray nozzles on the underside of the target permits extended operation times, e.g. up to about 16 hours, without such plugging problems. If desired, however, there may also be provided in the scrubbing apparatus of the present invention a second spray assembly 27 positioned above the target which may be activated periodically by actuating device 29, a pressure drop control, for instance about every 8 to 16 hours for a 1 to 3 minute period, to direct a downward spray on the target and thus irrigate the packing material and provide for continuous operation.

The absorber or reaction zone 30, as shown, is advantageously designed for intimate contact of countercurrently flowing gas and liquid streams, although it may be designed for concurrent ow if desired. As shown, the

absorber section is illustrated with two substantially horizontally disposed sieve trays, e.g. which can be of a conventional type. Bubble cap trays can also be used. The gases are passed through reactor 10 at a superficial velocity suicient to maintain liquid on the contact trays therein but not so great as to blow liquid out of the reactor. Typical average superficial velocities of the gases through absorber section 30 of reactor 10 are generally at least about 1.5 feet per second (f.p.s.) and advantageously from about 2.0 to 8.5 f.p.s. The cesium sulfte solution is introduced into reactor 10 through line 16, generally at a rate of from about 0.1 or 0.4 to 20 g.p.m., preferably from about 2 to 8 Ig.p.m., for each 2000 c.f.m. of gas, and the cesium bisulfite solution is removed through line 18. Cesium sultte, generally from about 75 to 95 weight percent, e.g. percent, of the total solution to be introduced, is conducted from line 16 through line 16'" and line 44 of demister 40, described below, to fall onto the surface of tray 32 and flow from tray 32 onto tray 34. Additional solution can be added, if desired, through line 16. The cesium sulte reacts with the sulfur dioxide in the gases passing through the sieve trays to produce an aqueous solution of cesium bisulte which passes from tray 34 into the catch `basin formed by downwardly projecting bale 36 from which it is removed through line 18. The sulfur dioxide content of the gas is substantially reduced, for instance, to less than about 0.02 mole percent in a stack gas containing more than about 0.2 mole percent.

The temperature of the solution in absorption or reaction zone 30 should be maintained above the temperature at which sulfur dioxide is absorbed by reaction with the aqueous solution of cesium sulte, and below the temperature at which cesium bisuliite decomposes, e.g. below about 230 F. With stack or furnace gases, however, the temperature of the solution will generally be above about 90 F. or 100 F. Since the stripped ilue gas is ultimately, after processing in demister zone 40, discharged into a stack, it is desirable to maintain the temperature of the stripped gases at a temperature sufliciently high to maintain their buoyancy so that they will rise in the stack, e.g., above about 185 F. At lower temperatures, e.g. 135 F., a fan can be used to draw off the gas. Generally the temperature of the gas from the absorber zone 30 into demister Zone 40 ranges from about 120 to 180 F., e.g. F. The temeprature of the stripped gas in line 14 out of the demister generally ranges from about 110 to F., e.g. 130 F., but it can be increased, if desired, by the introduction of a hot furnace gas through line 14. Generally the gas out of the demister is from about 85 to 100% saturated with water.

Cesium sulte solution is also advantageously sprayed against the underside of trays 32 and 34 by spray elements 38. Elements 38 are located generally from about 4 to 18 inches, e.g. 9 inches, from their respective trays. The velocity of the liquid is suficient to overcome gravity. As the cesium bisullite solution is formed on the trays, water is stripped from the solution by the hot ue gases which tends to supersaturate the solution and crystallize cesium bisulte and plug the trays. Cesium sulte solution from line 16 is passed to the spray elements through line 16". The sprays are directed against the bottom of the trays where the hot ue gases first contact the trays, since at this point most evaporation of Water occurs and, therefore, crystallization. A suicient amount of solution is sprayed upwardly against the under or contact surface of the trays to keep the solids dissolved in the solution on the trays, particularly at the surface where the flue gases impinge and thus advantageously provide for continuous operation of the process. It is desired to keep the amount of solution passed to the spray elements as low as possible and generally the amount of solution is less than about 0.1, or 0.4 g.p.m. per 2000 c.f.m. The higher the temperature of the waste gases, the higher the rate of solution required to be fed to spray elements 38. For example, with gases entering reactor at 300 F., about 0.1 to 0.2 gpm. per 2000 c.f.m. of gas is suitable.

The cesium sulte solution is passed through the absorber section 30 in an amount suflicient to react with the sulfur dioxide in the flue gas, i.e., absorb the sulfur dioxide in the solution, and produce cesium bisulte. Generally these are stoichiometric amounts and advantageously a solution containing about 25 weight percent cesium sulte and 25 weight percent cesium bisulfite can be employed.

The solution if cesium sulfite introduced into the reaction zone is preferably a recycle stream and, generally, contains from about 30 or 40 to 75, preferably about 40 i or 50 to 65 weight percent solids of which generally at least about 50 percent, desirably above about 75 percent, is cesium sulte and the balance is essentially cesium bisulte with, possibly, some sulfate. This recycle stream is preferably a saturated solution of cesium sultite. The cesium suliite solution can contain a suicient amount of an oxidation inhibitor, for instance hydroquinone, eg., about 0.001 to 0.1 percent, to inhibit the oxidation of the sulte ion. The temperature of this stream is controlled to avoid upsetting the requirements of reactor 10. The temperature of the recycle stream is typically from about 90 to 160 F. In general, a sucient amount of cesium sulte solution is contacted with the waste gas in reactor 10 to remove as much of the sulfur dioxide as possible, desir ably above about 90 to 95 percent, and the residence time of the solution in the reactor, etc., is adjusted accordingly. The solution flow rate in absorber zone 30 is normally maintained suiciently fast, and the residence time of the solution in absorber zone short enough, that crystallization problems do not occur Within the absorber zone. With a slow ow rate and a high residence time, absorption of sulfur dioxide will occur; however, the solution becomes very concentrated and, therefore, the danger of crystals depositing from the solution and plugging the sieve trays is increased. The flow rate of the solution will depend upon the temperature of the gas, the amount of SO2 in lthe gas, the temperature and concentration of the cesium suliite solution, it will, however, generally range from about 0.1 to gpm., preferably from about 2 to 8 g.p.m. per 2000 c.f.m. of gas. Baiile 36 forms a collector trough or catch basin for the cesium bisulte solution. Bafe 36 can be sloped, e.g. from about 10 to 45, or horizontal, so that any crystals contained in the cesium bisuliite solution will flow downwardly toward line 18. A relatively thick layer, e.g. a few inches (e.g. 8 inches) or several feet, of solution is maintained on baffle 36 to avoid formation of crystals in the solution and, preferably, the hold-up time in the catch basin is short, for instance generally from about 5 to 10 minutes.

The product of the reaction zone is preferably a saturated solution of cesium bisulte, and, accordingly, the concentration of the solution is desirably maintained at just below saturation by the addition of suicient water to avoid precipitation of cesium bisulte.

The amount of solids in the solution will vary depending upon the temperature, but it is generally maintained suiiiciently high for eiiicient sulfur dioxide recovery. There will generally be between about 40 or 45 and 75 weight percent, preferably between about 45 or 50 and 55 or 65 weight percent, solids in the solution. The amount of cesium bisulfite and cesium sulte in the solids will vary depending upon the total percentage of solids and the temperature of the solution. In general, about 5 to 50 or 60 weight percent, preferably 10 to 3S or 50 weight percent, is cesium bisulite and generally 40 or 50 to 95 weight percent, usually about 50 or 65 to 90 Weight percent, is cesium sulte.

The stripped flue gases in reactor 10 pass from absorption reaction zone 30 to the moisture entrainment or demister zone 40 which includes a woven mesh contact area. The pressure drop of the gas through zone 30 will generally range from about 1.5 to 4.5, e.g, 2.5, inches of water at 2000 c.f.m. of gas. The woven mesh 42 is a material chemically inert to the components of the system, eg. 304 stainless steel, and similar in structure and appearance to steel wool; it is shown in FIG. 2 as being retained on a column support 43. Cesium sulte solution from line 16 passes through line 16"', and lines 44' and 46 to nozzles 44 and 46, respectively, generally positioned from about 4 to 18 inches, e.g. 9 inches, from 42, which continuously spray the solution onto the woven mesh 42 from opposite sides of the assembly, Le., top and bottom, to advantageously avoid plugging problems and maintain a continuous operation. The demister zone 40 serves to remove droplets of solution from the gases exiting from reactor 10 to thereby limit chemical losses. The droplet can be liquid or solid forms of the reaction product generally small enough, for instance from about 1 to 100 microns in size, such that it can be supported in the velocity of the rising gas flow, normally between about 2 to 7 fps. It was surprisingly found that when the contact material referred to was of a woven mesh-like structure, small amounts of solution could be advantageously employed. However, a material providing a large amount of contact surface and a highly irrigatable contact surface, e.g. Raschig rings, can be employed but require larger amounts, e.g. 15 gpm. of solution. The thickness of demister zone 40, eg. about 1 to 4 inches, is suicient to remove droplets from the exit gases but not so large as to create a large pressure drop, and the gas iiow through demister zone 40 is below the point at which droplets from the contact area would be re-entrained. The maximum desirable pressure drop is generally in the range of about 1A to 1/2 inch of water and, typically, gas velocities of about 2 to 6 f.p.s. are suitable. Generally, solution is added to the demister zone in an amount sufficient to avoid plugging of the demister and insufficient for entrainment of the exiting gases. r[his demister embodiment is highly eflcient and only requires the use of small amounts of solution. For example, generally about 2 to 5 or 6, preferably about 3 to 3l/z, or 4, gpm. of solution per 2,000 c.f.m. of gas flow are suitable, being divided preferably equally between nozzles 44 and 46. The amount of solution used will decrease with decreasing concentration of the solution and it is desirable to maintain the flow as low Vas possible. The demister zone 40 also functions to remove the last traces of sulfur dioxide contained in the exiting gases. For example, the demister normally removes an additional l'to 2% of the total sulfur dioxide in the incoming waste gases.

Referring to FIGS. 1 and 2 again, the cesium bisulte solution is removed from reactor 10 through line 18 to surge tanl; 48 from which it is pumped (eg. generally having only a residence time of only about 5 to 20 minutes in the surge tank) expeditiously to avoid substantial cooling and crystallization and plugging Within the tank. It is pumpedI through line 52 by pump S4 to the ash cooler-crystallizer zone S0. Line 18 has a vacuum breaker line 18 associated with it. The solution pumped through line 52 may, if desired, be passed through a filter 56 to remove solids from the solution.

The flash cooler-crystallization zone 50 includes a ilash chamber 58 wherein the solution can be advantageously cooled by vaporization of water from the solution, and a crystallization tank 60. Flash chamber 58 is maintained under vacuum, generally of about 0.5 to 4 p.s.i.a., usually from about 0.8 to 1.5 p.s.i.a., by steam injectors 62 and 64. Such ejectors can draw a vacuum of about 0.5 p.s.i.a. As shown, steam ejectors 62 and 64 draw a vacuum on the chamber SS through line 66. The pressure in chamber 58 is controlled by the addition of air through line 68 to control the temperature of the solution. The control of the pressure in turn controls the boiling point and temperature drop, and therefore the temperature of the solution in the flash chamber and the amount of water vaporized from the solution. Heat exchanger 70 in line 66 condenses the water evaporated from the solution in chamber 58.

The condensate passes through line 72 for use in dissolving the cesium pyrosulfite crystals. The steam from ejectors 62 and 64 is also condensed and passed through lines 74 and 76 for later use in the system.

The solution in chamber 58 is normally cooled to a temperature suliicient to crystallize, i.e., remove from solution, a sufiicient amount of cesium pyrosulfite to compensate for the sulfur dioxide absorbed from the gas stream in line 12 and thereby maintain a proper balance of solids in the solution for recirculation thereof. The amount of cesium pyrosulfite crystals removed depends upon the conversion of cesium sulfite to bisulfite in the reactor. The temperature drop in chamber 58 is determined by control of the inlet temperature of the solution, the pressure within chamber 58, residence time of the solution in chamber 58 (e.g. generally from about 15 minutes to 2 hours), recycle ratio, etc. Since temperatures of the inlet solution generally are in the range of about 80 to 200 F., usually from about 130 F. to 160 F. for power plant type gas processing and usually from about 80 F. to 110 F. for sulfuric acid plant type gas processing, temperature drops generally of -about 10 to 70 F., or 90 F., preferably about 30 to 50 F. or 70 F., may be desirable to crystallize the desired amount of cesium pyrosulfite. The amount of water removed in the fiash cooler from the system is advantageously used to maintain lthe water in the system in balance by correlation of the amount of water removed in the fiash cooler with the amount of water removed by the gas stream in the reactor. Although water can be easily removed in the fiash cooler, it requires an input of energy whereas if removed in the reactor, the energy used is only such as is normally present. Thus, a particularly attractive feature provided by prescrubber 20 resides in accomplishing the prescrubbing with liquid, e.g. water, while at the same time avoiding a significant drop in the temperature of the gas and a significant increase in the relative humidity of the gas; thus providing the gas in the -absorber zone at optimum temperatures and relative humidity for evaporating water from the system inexpensively and efficiently. In the event a gas stream having a low temperature and high relative humidity is employed and has limited capacity for absorbing water, great flexibility is provided for the system in that excess Water can be removed by the liash cooler.

The efficiency of the flash cooler in removing Water also provides for advantageous control of filtration conditions. The filtration system employed can be a simple rotary filter and advantageous control over the temperature and residence time of the solution can be obtained with facility to control the size of crystals to enhance filterability with increased filtration rates and provide crystals of greater purity, e.g. 99 percent pure. It also desupersaturates without nucleation and substantially avoid plugging problems which would characterize the use of a heat exchanger under the conditions of processing in the present system.

The cooled solution, or slurry, is passed from flash chamber 58 to crystallization tank 60 through line 78. The solution residence time within the crystallization tank 60 is sufficient to produce a proper size crystal for filtration, e.g., crystals larger than about 300 mesh and up to about 10 mesh. Generally a volume residence time of from about 5 minutes to 2 hours, or more, preferably of about minutes to 45 minutes are suitable for the production of crystals of the desired size. Suitable crystals to obtain would be where about 80 percent of the crystals are between 10 and 60 mesh using a 45 minute retention time. Another important factor in producing crystals of this desired size is the control of the pH of the solution, e.g. generally between about 6.6 to 7.4. The pH can be controlled by adjusting the specific gravity of the reaction solution conducted out of the reactor, for instance using density control device 69 in line 71. Recycle line 80 and pump 82 are provided to control the temperature and residence time of the solution. The bottom of fiash chamber 58 slopes and the line 78 extends to the bottom of tank 60 to avoid plugging by crystals formed in chamber 58 and tank 60. A demister 84, arranged in the upper section of flash chamber 58, is constructed and operates in a manner similar to demister 40 to remove entrained droplets in the gas passing through line 66.

The slurry of cesium pyrosulfite crystals formed in crystallization tank 60 is pumped by pump 86 through line 88 to a rotary drum vacuum filter, generally designated as 90. The drum filter includes a rotary drum 92 and a pan 94. The slurry is introduced into pan 94 through line 88 and drawn by a vacuum applied internally of drum 92 through the filter surface of the drum by vacuum pump 96. The filtrate solution drawn from filter drum 92 is passed through line 98 to filtrate tank where it is collected and from which it is subsequently pumped through line 102 by pump 104 to absorber feed tank 106.

The cesium pyrosulfite crystals retained on the filter surface on drum 92 are removed by a scraper or doctor blade 108 and passed to a dissolver tank 110. The filtration rate of the filter is maintained as high as possible while still obtaining a clear filtrate or solution leaving the filter through line 98. Filtration rates of about 900 to 4,000, preferably 1,500 to 3,000, pounds of crystals per hour per square foot of surface area of the filter are usually obtained. The higher the filter rate the smaller the surface area of the filter required. The size of the filter cloth used can be important in maintaining a clear filtrate. For instance, if crystals filter through the cloth, the pH of the filtrate solution will drop, e.g. to a pH of about 6.3, and thus adversely affect the recycle stream by deterring the absorption of SO2 as a result of an increase of the bisulte. The vacuum applied to the drum ffilter by pump 96 is maintained so that the vacuum applied at drum 92 is less than the vacuum, e.g. higher pressure, applied in chamber 58. To use a lower pressure at this point in the system would additionally cool the solution to crystallize additional cesium pyrosulfite inside drum 92 which would plug the system. The filter screen utilized on drum 92 is preferably a monofilament cloth, e.g., nylon, chemically inert to the solution and slurry, which has openings generally of about 10 to 50, or 60 microns in size, preferably about 20 to 40 microns in size. The crystals can be advantageously washed by spray 112, preferably using a side stream of the 50 percent solution being conducted to the stripper column, on the filter surface to further enhance the purification of them. lSince the 50 percent cesium bisulfite solution would be saturated, substantially none of the crystals are dissolved and the purity of the crystals are increased by displacement Washing of the mother liquor. Also, if desired, a steam sparg or blowback 114 can be applied to the filter surface near scraper blade 108 to clean the filter surface by removing any crystals not removed by blade 108.

The cesium pyrosulfite crystals can be advantageously heated in the presence of water to enhance their decomposition to produce sulfur dioxide at relatively low ternperatures. The water employed can be residual water of the mother liquor contained -by the crystals or it can be added water; it can be in any suitable form, e.g. liquid or vapor form; and it is used in amounts .sufficient to enhance the decomposition of the cesium pyrosulfite to produce sulfur dioxide. These amounts are at least about 0.01 weight percent, generally from about 1 to 99 weight percent and advantageously from about 20 to 75 weight percent based on the cesium pyrosulfite and Water. In amounts up to about 20 weight percent water, damp crystals are provided and in amounts of about 40 Weight percent, for instance, a solution can be provided.

The crystals passed into tank 110 are dissolved in sufficient Water for ease of handling. Generally, enough water is added to at least form a slurry which is pumpable, e.g., contains about 60 to 70% solids, although, if desired, suicient water can be added to form a solution. Density control means 103 controls the amount of solids in solution in 110. Generally, about 35 to 55%, preferably about 40 to 50%, solids are in the solution which is removed from dissolver 110 through line 116 by pump 118. Water is supplied to dissolver 110 in the form of condensate from the cooler 70 via line 72 and via lines 74 and 76 from the steam eectors 62 and 64, respectively. Fresh water can be added through line 120, if desired.

The cesium bisullite solution in line 116 is passed to stripper zone, designated generally as 125, where the soltuion is heated to a temperature, e.g. 230 to 300 F., sucient for decomposition of the cesium bisulfite to produce sulfur dioxide and a cesium sulte solution. The decomposition is advantageously accomplished in a multiple effect stripping operation to increase the overall conversion of cesium bisulte to cesium sulfite and reduce the energy, i.e. steam requirements of the system. As illustrated, stripper zone 125 includes two stripping columns 122 and 122', although, if desired, three or more effects may be used. The solution fed to column 122 through line 116 is heated by steam in reboiler 138 to a temperature suicient to decompose the cesium bisulfite in the solution to produce an overhead gas stream comprising sulfur dioxide and water vapor. This overhead stream is removed through line 124 and passed to reboiler 138 for the second stripper column 122 to provide the necessary energy therein for decomposition of additional cesium bisulfite. The conversion of cesium bisulrite to cesium sulte in any particular stripper column is limited, since once the partial pressure of Sulfur dioxide in the vapors within the column equals the partial pressure of sulfur dioxide in the solution, no additional sulfur dioxide can be removed from solution regardless of the energy supplied to the column. When using several co1- umns fresh steam is produced in each column by removal of water from the solution which can be saturated with additional sulfur dioxide whereby additional decomposition of cesium bisulfite and improved conversion are obtained. Additionally, the energy or steam requirements of the system are reduced b'y recovering energy from the vapors produced in eaoh stripper column through the use of these vapors to provide heat for the succeeding column. Following reboiler 138' wherein the water vapor in line 124 will be mostly a condensed product, this product is passed through line 126 to separator 128. The condensed water is removed from the bottom of seperator 128 through line 130 and the sulfur dioxide as a product gas through line 131. The partially decomposed cesium bisulte solution is Withdrawn from column 122 through line 134 and passed by pump 136 to column 122 wlhere additional cesium bisulte is decomposed. Overhead vapors are removed from column 122 through line 124' and heat exchanger, i.e. cooler-condenser 126 to tank 128. Condensed water vapor is removed from separator 16 through line 142 to feed inlet line 16 for reactor 10. The Water separated in lines 130 and 130 is passed to dissolver 110 for use in dissolving cesium pyrosulte crystals.

The first effect separator column is generally operated at an elevated pressure and temperature suicient to decompose the cesium bisulfite, for instance up to about 200 p.s.i.a. and 600 F., but preferably below temperatures at which substantial amounts of cesium sulfate form, e.g. 400 F., and below pressures of about 150 p.s.i.a. Typically, the rst elect separator 122 is operated at a temperature of about 275 to 350 F., or 400 F., and a pressure of about 40 to 80 p.s.i.a., preferably about 40 to 460' p.s.i.a. These conditions are chosen to hold the steam requirements down, that is, the amount of steam required to produce the desired amount of sulfur dioxide. In general, it is desired to hold the steam requirements Within about 2 to 6, preferably about 2 to 4 pounds of steam per pound of sulfur dioxide. Each of the succeeding effects will operate at a pressure of about 20 p.s.i.a. less than the preceding effect and at corresponding decomposition temperatures. For instance, the second effect separator column in a two effect system will generally operate at a pressure of about 20 to 60 p.s.i.a., preferably about 20 to 40 p.s.i.a., and a temperature of about 250 to 300 F., preferably 260 to 280 F.

When it is desired to remove cesium sulfate, an undesirable byproduct of the process, from the cesium bisulte, a portion of the solution in line 116 can be diverted through line 144 Where a centrifuge 146, or, if desired, a filter, separates the cesium sulfate crystals through discharge line 147. If a slurry of cesium bisulte is used as feed to stripper column 122, the diversion and separation of cesium sulfate can be accomplished in line 134' or line 142.

The nature of the system and its Operation is such that it is not adversely affected by the cyclic nature of plant operations, the temperature of gases to be processed (e.g. drop in temperature of power plant gases in the evening), or the sulfur or solids content of the gas, and thus provides great flexibility. Thus it can purify any gas containing SO2, S03 or particulate solids or any other similar types of components in any type of gas which is compatible with the system and will not be deleteriously affected by, or deleteriously affect, the system.

The SO2 recovery system described above and in the attached drawings was employed in the treatment of 'ue gas from a coal-burning power plant. To evaluate the temperature drop of the incoming ue gas after being routed through the prescru'b'ber, several runs were made at varying ratios of scrubbing Water to Waste gas. In each run the flue gas was introduced to the prescrubber at a ow rate of about 2000 cubic feet per minute and at a temperature of about 300 F. The temperature and humidity of the gas as it exited the top of the impingement target was recorded. Results are presented` in Table I below:

tank 128' through line 130 and sulfur dioxide as a product gas through line 131'. The stripper bottoms, which is now a cesium sullite rich solution, is conveyed through line 134 by pump 136 to the absorber feed tank 106. A portion of the stripper bottoms in line 134 is passed through reboiler 138 to maintain proper temperature, e.g. generally from about 230 to 300 F., within the stripper column 122. The cesium sultite solution collected The following table, Table II, sets forth a specific example of this process within the conditions and parameters set forth in the discussions referring to FIGS. l and 2 of the drawing and using essentially the same specific examples noted in the drawings, the table giving specific compositions of the streams for the various flow lines in the absorber feed tank 106 is pumped by pump 140 75 and prevailing temperatures. The flue gas is of a typical 17 composition in mole percent; sulfur dioxide, 0.3%; oxygen, 3.4%; water vapor, 6.0%; carbon dioxide, 14.2%; nitrogen, 76.1%; and sulfur trioxide, 0.0003%. The vacuum type ash cooler is operated at 1 p.s.i.a. and 104 F., water is removed from the ash cooler at a rate containing sulfur dioxide and an aqueous solution of a metal sulte selected from the group consisting of cesium suliite and rubidium sulfite in a reaction zone to produce an aqueous solution of the corresponding =bisu1te, the

reaction zone being maintained at a temperature suffiof about 140 pounds per hour and the pH of the solution cient to react the sulfur dioxide with the sulfte and 1n the crystallizer is about 7.0 to 7.2. below the temperature at which bisulite decomposes to TABLE II Flue Into Flue Absorber Absorber Crystal gas, absorber gas, feed discharge discharge Filtrate Process stream line 12 30 line 14 line 16 line 18 blade 108 line 102 SO2, lbS./mn 0. 644 0. 644 0.064 15. 03 CS2S205,1bS./mln 13. 25 CszSOa, lbs./min- 18.21 Cs2SO4, lbs./min 1. 77

O3, mol percent H10, lbs./min X+5. 0 35. 10 Solids, lbsJmi 33. 23 Total, lbs/min 114. 4 67. 33 Flue gas, a.c.f.m 2, 010 1, 550 Fly ash, grains/ft.s l 0. 3 G. .ru 5.6 Specific gravity 1. 44 Temp., F 300 255 125 150. 0 pH.. 7.2 Relative humidity, percent 6 l 8 Combined Combined stripper stripper Stripper column column Stripper column overhead, product, column Water feed to feed, lines 124 lines 131 bottoms, prescrubber, Process stream line 116 and 124 and 131 line 134 line 24 SO2, lbs/min 0528205, lbS./II111 CszSOi, lbs/min...

1 1.5 grains per cubic foot into an electric precipitator and 0.3 grain out of the electric precipitator.

i Out of absorber zone 3D, the relative humidity is 83%.

EXAMPLE II An aqueous solution containing about 48 weight percent Cs2'SO3 is reacted with a flue gas having the typical composition in mole percent; sulfur dioxide, 0.3%; oxygen, 3.4%; water vapor, 6.0%; carbon dioxide, 14.2%; nitrogen, 76.1%; and sulfur trioxide, trace. The solution has an average residence time in reactor 10 of about 8 to 12 seconds per tray advantageously, although it can range from about 1 to 600 seconds if desired, an inlet ternperature of about 100 F. and an outlet temperature of about 180 F. About 95 percent of the sulfur dioxide is removed from the ue gas. The solution removed from reactor 10 is an aqueous solution containing about l0 weight percent Cs2HSO3 and 40 weight percent Cs2SO3. This solution is cooled in crystallizer 50 to about 104 F. which reduces the CsHSO3 content to about 7 weight percent, the remaining 3 weight percent precipitating as Cs2S2O5. The residence time in the crystallizer is generally from about 1 to 120 minutes, preferably about 5 to minutes and in this example it is 10 minutes. The percipitated CS2S2O5 is separated by ller 90 and passed to dissolving tank 110 and then to stripper 122. Sulfur dioxide evolves and is collected. The Cs2SO3 also produced is recycled into reactor 10. When the solution in crystallizer 50 is cooled, the Cs2S2O5 content is substantially reduced.

EXAMPLE III Essentially the same procedure used in Example II is followed except an aqueous solution of rubidium sulte is used instead of cesium sulte to produce rubidium bisulte and recover SO2.

It is claimed:

1. A process for the recovery of sulfur dioxide from a gas containing the same, comprising reacting said gas sulte, cooling the solution of bisulte to a temperature at which at least a portion of the bisulte therein crystallizes as the corresponding pyrosulte having a purity greater than about 65% separating the pyrosulfite crystals, heating separated pyrosulte which may be in aqueous solution as bisullite, to a temperature sufficient to decompose the pyrosulfite or -bisulte to sulte and sulfur dioxide, and recovering resulting sulfur dioxide.

2. The process of claim 1 including recycling to the reaction zone (a) the sulte produced upon decomposition of the pyrosulfite or bisuliite and (b) the solution of bisulte remaining after separation of the crystals.

3. The process of claim 1 wherein said reaction zone temperature is below about 230 F.

4. The process of claim 1 wherein the solution of bisulte is cooled to below about F.

5. The process of claim 1 wherein the decomposition temperature is Vbetween about 230 and 600 F.

6. The process of claim 2 wherein said reaction zone temperature is lbelow about F., the `solution of bisulite is cooled to below about 110 F., and the decomposition temperature is between about 300 F. and 400 F. 7. The process of claim 1 wherein said aqueous solution of sulte added to the reaction zone is a substantially saturated solution, the solids content of which coritains 75% to 100% sulte with the balance being essentially the corresponding bisulte.

8. The process of claim 7 wherein the aqueous solution of bisulite produced in said reaction zone contains about 45 to 75 weight percent solids of which about 5 to 60 weight percent is bisulite and the balance essentially sullite.

9. The process of claim 8 wherein said reaction zone temperature is below about 230 F., the solution of ybisulte is cooled to below about 110 F., and the decomposition temperature is between about 100 F. and 600 F.

10. The process of claim 9 wherein the solution remaining after separation of said crystals is recycled to the reaction zone.

11. The process of claim 10 wherein the sulte produced upon decomposition of said pyrosullite or bisuliite is recycled to the reaction zone.

12. The process of claim 9 wherein the aqueous solution of bisulfite produced in the reaction zone contains about 50 to 65 weight percent solids of which about l0 to 35 weight percent is the corresponding bisulte.

13. The process of claim 1 wherein the aqueous solution of sulte contains an oxidation inhibitor for the reaction of sulfite ion and oxygen.

14. The process of claim 1 wherein the metal sullite is cesium suliite.

15. The process of claim 1 wherein the metal suilite is rubidium sulfite.

16. A process for recovering sulfur dioxide from sulfur dioxide-containing gases comprising contacting the gas with an aqueous solution of metal sulte selected from the group consisting of cesium sulfite and rubidium suliite, at a temperature sufficient to produce an aqueous solution of the corresponding bisulite which is a precursor of sulfur dioxide and in the solution is in contact with SO2 partial pressure-lowering metal salt; separating sulfur dioxide precursor in the form of the corresponding metal pyrosulte crystals having a purity greater than about 65% from said metal salt to increase the partial pressure of the sulfur dioxide in the precursor; heating the precursor, which may be in the form of pyrosulte or bisullite, at temperatures suliicient to produce sulfur dioxide, and recovering sulfur dioxide.

17. The process of claim 16 wherein the sulfur dioxide-containing gas contains 0.001 to 5 mole percent sulfur dioxide.

18. The process of claim 16 wherein the metal sulite is cesium suliite.

19. The process of claim 16 wherein the metal sulte is rubidiurn suliite.

20. A process for recovering sulfur dioxide trom a sulfur dioxide-containing gas comprising contacting the gas with an aqueous solution of metal sulite selected from the group consisting of cesium sulte and rubidium sullite at a temperature below about 230 F. and suliicient to produce an aqueous solution of the corresponding bisulte which is a precursor of sulfur dioxide and in the solution is in contact with 4SO2 partial pressure-lowering metal salt; crystallzing the precursor out of the solution, which precursor transforms to pyrosuliite during crystallization and has a purity greater than about 65%, separating said precursor from amounts of metal salt suficient to result in an increase of the partial pressure of the sulfur dioxide in the precursor, heating the purified precursor, which may be in the form of pyrosulte or bisulte, at a temperature greater than about 100 F. and suliicient to produce sulfur dioxide, and recovering sulfur dioxide.

21. The process of claim 20 wherein the purified sulfur dioxide precursor is heated in the presence of Water in amounts suicient to enhance the decomposition of the precursor to produce sulfur dioxide.

22. The process of claim 21 wherein the suliite solution contains from about 30 to 75 weight percent solids of which at least about 50 percent is sullite; the pyrosulte is provided at a purity greater than about 90 weight percent and the precursor is heated in the presence of about 0.01 to 99 weight percent water based on the pyrosuliite and water, at a temperature from about 100 F. to 375 F., and a pressure from about to 300 p.s.i.a.

23. The process of claim 21 wherein the precursor is heated in the presence of about to 50 weight percent water at a temperature from about 230 F. to 375 F. and a pressure from about to 150 p.s.i.a.

24. The process of claim wherein the purified sulfur dioxide precursor in the form of pyrosulite is heated under essentially anhydrous conditions.

25. The process of claim 24 wherein the sullite solution contains from about 30 to 75 weight percent solids of which at least about 50 percent is sultite; the pyrosuliite is provided at a purity greater than about weight percent and the precursor is heated at a temperature from about 230 F. to 400 F.

26. The process of claim 25 wherein the precursor is heated in the presence of suliicient amounts of a chemically-inert heating liquid to occlude sulte produced during the heating and limit contact of the sulfite with the desired sulfur dioxide.

27. The process of claim 26 wherein the liquid is mineral oil and is used in amounts from about 10 to 90 weight percent.

28. The process of claim 16 wherein the reaction zone includes at least one fluid permeable, open, substantially horizontally disposed, liquid hold-up type contact tray, the metal sulite solution is on the tray, the gas is conducted in a generally upward direction in the reaction zone to the contact tray at a superficial velocity sutiicient at the time of contact with the tray to maintain the solution on the tray and insufficient to entrain substantial amounts of the solution, and the surface of the tray rst contacted by the gases is sprayed with the solution in an amount suflicient to substantially maintain salts on the surface of the tray in solution.

29. The process of claim 28 wherein the rate of ow of the solution of metal suliite through the reaction Zone is about 0.1 to 20 gpm. per 2,000 c.f.m. of gas, of which about 0.1 to 0.4 g.p.m. per 2,000 Cim. is sprayed against the surface of the tray, the reaction zone temperature is below about 230 F., and the superficial velocity of the gas through the absorber zone is above about 1.5 f.p.s.

30. The process of claim 16 wherein the SO2 lean gases resulting from contact with the aqueous metal sulte solution is conducted to an entrainment zone containing a woven mesh contact material at a gas iiow rate suicient to penetrate into a gas-receiving side of the material, permeate it and pass out of a gas emitting side of the material, and insufiicient to entrain solution, and the Woven mesh contact material on a gas receiving side and a gas emitting side is sprayed with a washing solution in an amount sutlicient to wet the contact material, prevent plugging, and scrub from the SO2 lean gas at least a portion of the sulfur dioxide remaining in the gas.

31. The process of claim 30 wherein the washing solution is an aqueous solution of the metal sulte suitable for use in the reaction zone, and the process includes passing the aqueous solution containing the removed sulfur dioxide and entrained material to the reaction zone, the gas flow through the entrainment zone is about 2 to 7 f.p.s., and the SO2 lean gas contains entrained droplets from about 1 to 100 microns in size.

32. The process of claim 16 wherein the gases contain contaminants other than SO2 and is prelminarily treated to recover one or more contaminants selected from the group consisting of liquid-soluble and entrained particulate solid components wherein the gas is conducted in a generally upwardly direction in a scrubbing zone to a substantially horizontally disposed, duid-permeable, irnpingement target forming a discontinuous surface for retention of entrained solids in the gas, the target having a tiuid receiving side and a fluid emitting side, the gas is conducted to a uid receiving side of the target at a supercial velocity suflicient at the time of contact with the target to permeate and pass through a tiuid emitting side of the target in substantial amounts, the -gas is conducted to the target in the presence of, and concurrently with, a liquid being conducted to the target at a supercial velocity suflicient to contact and wet the target, the amount of liquid used is sutiicient to transfer liquid-soluble components in the gas to the liquid and to transfer particulate solids entrained in the gas to the liquid, the

liquid containing contaminant is removed, and the gas is conducted to the reaction zone.

33. The process of claim 32 wherein sufficient amounts of liquid are used to form droplets containing contaminant which droplets fall oi of the target and are removed from the scrubbing zone; the liquid is chemically inert to, and is continuously directed to the underside of the target; and the gas is at a temperature up to about 800 F., is conducted to the target at a velocity to have at least 60 volume percent of the gas permeate and pass through the target, and contains particles having a size from about 0.5 to 50 microns.

34. The process of claim 33 wherein the particulate solids in the gas include ily ash; the liquid-soluble components include S03; the liquid is water; the solids loading in the gas is from about 0.5 to 30 grains per cubic foot of gas and liquid-soluble components are present in an amount from about 0.0001 to 0.01 mol percent when liquid soluble components are present in the gas; the gas is introduced at a temperature of up to about 800 F. and at a distance from about 5 to 70 inches from the spraying means; the liquid is conducted to the target in an amount of 0.01 to 1 g.p.m. per 2,000 c.f.m. of the gas; the target is composed of packing whose particles have a longest dimension from about 0.25 to 3.5 inches and is irrigated intermittently by irrigating liquid conducted downwardly to the target.

35. The process of claim 34 wherein the gas is preliminarily treated in a scalping operation to remove substantial amounts of particulate solids; the water is at a temperature from about 50 to 120 F.; and the gas is at a temperature of about 150 to 600 F., has a relative humidity of up to percent and solids having a size from about 0.5 to 50 microns.

36. The process of claim 32 wherein the reaction zone includes at least one uid permeable, open, substantially horizontally disposed, liquid hold-up type contact tray, the metal suliite solution is on the tray, the gas is conducted in a generally upward direction in the reaction zone to the contact tray at a superficial velocity sufficient at the time of contact with the tray to maintain the solution on the tray and insufficient to entrain substantial amounts of the solution, the surface of the tray first contacted by the gases is sprayed with the solution in an amount sufficient to substantially maintain salts on the surface of the tray in solution.

37. The process of claim 36 wherein the SO2 lean gases following contact with the aqueous metal suli'ite solution is conducted to an entrainment zone containing a woven mesh contact material at a `gas 110W rate sufficient to penetrate into a gas-receiving side of the material, permeate it, and pass out of a gas emitting side of the material, and insuicient to entrain solution, the woven mesh contact material on a lgas receiving side and a gas emitting side is sprayed with a washing solution in an amount sufficient to wet the contact material, prevent plugging, and scrub from the SO2 lean gas at least a portion of the sulfur dioxide remaining in the gas.

38. The process of claim 32 wherein the gas is introduced into the prescrubbing zone outwardly of the wall a distance of at least one inch at an angle of about 5 to from the horizontal.

39. The process of claim 37 wherein the lgas is introl duced into the prescrubbing zone outwardly of the wall a distance of at least one inch at an angle of about 5 to 60 up from the horizontal.

40. The process of claim 1 wherein the gas contains sulfur trioxide 'with or without entrained particulate solids and is preliminarily treated for purifying the gas by removal from the gas of sulfur trioxide with or without said entrained particulate solids.

41. The process of claim 40 in which the removal is by contact of the gas with water.

42. The process of claim 41 wherein entrained particulate solids are in the gas and include y ash, and the contact with water removes both fly ash and sulfur trioxide from the gas.

43. The process of claim 16 wherein the gas contains sulfur trioxide with or Without entrained particulate solids and is preliminarily treated for purifying the gas by removal from the gas of sulfur trioxide with or without said entrained particulate solids.

44. The process of claim 43 in which the removal is by contact of the gas with water.

45. The process of claim 44 wherein entrained particu'- late solids are in the gas and include y ash, and the contact with water removes both ily ash and sulfur trioxide from the gas.

References Cited UNITED STATES PATENTS 1,589,133 6/1926 Eustis 23--178 FOREIGN PATENTS 134,555 11/1919 Great Britain 23--178 S 489,745 8/ 1938 Great Britain 23--178 S OTHER REFERENCES Perry, Chem. Engrs. Handbook, 4th ed., sect. 17, pp. 10, 11; sec. 9, pp. 53, 54; sec. 18, pp. 4, 5, 86; sect. 20, p. 82 (McGraw-Hill, 1963).

Bettelheim, Chem. Abs., vol. 55, p. 21733a (1961).

Bodor et al., Chem. Abs., vol. 57, p. 4505b (1962).

Epifana et al., Chem. Abs., vol. 58, p. 1199515 (1963).

V. Chertkov, Chem. Abs., vol. 55, p. 17116e (1961).

OSCAR R. VERTIZ, Primary Examiner C. B. RODMAN, Assistant Examiner U.S. Cl. X.R. 423-583 

